Chrysler Caravan/Voyager/Town and Country 1996-1999

Fuel Filter

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4 and 5


CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.



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Fig. Fig. 1: The fuel filter (1) is mounted next to the fuel pump module (2), on top of the fuel tank (3)

The fuel delivery system uses quick-connect fittings. The fuel filter mounts to the top of the fuel tank.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Place a drain pan underneath the fuel filter to catch any spilling fuel that will result from disconnecting the fuel lines.
  8.  

It may be necessary to support the weight of the fuel tank with a block of wood and a floor jack. Once this is accomplished, loosen, but do not remove, the fuel tank strap bolts. Allow the fuel tank to lower just enough to access the fuel line fittings at the fuel pump module.



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Fig. Fig. 2: Disengage the fuel line quick-connect fittings from the fuel pump module



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Fig. Fig. 3: Be sure to place a drain pan underneath the filter line fittings to catch all fuel spillage

  1. Locate the fuel filter in its mounting on top of the fuel tank. Detach the quick-connect fittings from the chassis fuel supply tube and fuel pump module by squeezing the quick-connect fitting retainer tabs together and pulling the fitting assembly away from the fuel line nipple. The retainer will remain on the fuel tube.
  2.  



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Fig. Fig. 4: Using a 10mm socket, remove the fuel filter mounting bolt ...



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Fig. Fig. 5: ... then remove the fuel filter from the top of the fuel tank

  1. Remove the fuel filter mounting bolt and remove the fuel filter from the fuel tank.
  2.  

To install:
  1. Install the fuel filter on the top of the fuel tank and tighten the mounting bolt.
  2.  
  3. The fuel supply tube (to chassis fuel line), return tube (to pump module) and fuel supply (to fuel filter) tube are permanently attached to the fuel filter. The quick-connect fitting ends of the fuel supply and return tubes are of different sizes.
  4.  
  5. Apply a light coating of 30W engine oil to the nipples of the fuel filter.
  6.  
  7. Push the quick-connect fitting over the fuel line until the retainer seats and clicks into place. Be sure the retainer tabs have locked into the case of the fitting.
  8.  
  9. If necessary, raise the fuel tank and tighten the fuel tank strap bolts.
  10.  
  11. Lower the vehicle. Start the engine and check for leaks.
  12.  

 
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